Toyota RAV4 1999 Manual
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Toyota RAV4 1999 Manual

Air bag restraint system
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DESCRIPTION & OPERATION
WARNING:
To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and SERVICE PRECAUTIONS .
Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident
protection for driver and passenger by deploying air bags in a front-end collision. The air bag system is
designed to be used in conjunction with 3-point safety belts.
The air bag system includes the following components: driver-side air bag module (steering wheel pad),
passenger-side air bag module, spiral cable, AIR BAG warning light, air bag sensor assembly, right and left
front air bag sensors, right and left front seat belt pretensioners and associated wiring harnesses. See Fig. 1 .
1999 Toyota RAV4
1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
AIR BAG RESTRAINT SYSTEM 1999 Toyota
AIR BAG RESTRAINT SYSTEM
1999 Toyota

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  • Page 1 1999 Toyota RAV4 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota AIR BAG RESTRAINT SYSTEM 1999 Toyota AIR BAG RESTRAINT SYSTEM 1999 Toyota DESCRIPTION & OPERATION WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and SERVICE PRECAUTIONS .

  • Page 2: Service Precautions

    AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 1: Locating Restraint System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR BAG SENSOR ASSEMBLY The air bag sensor assembly is located on the floor inside center console box. It consists of an air bag sensor, safing sensor and diagnosis, ignition control and drive circuits.

  • Page 3: Spiral Cable

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota may allow air bag to deploy until 90 seconds after disconnecting negative battery cable. If vehicle was in a minor collision but air bags did not deploy, inspect all system components for any sign ...
  • Page 4 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 2: Adjusting Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISABLING & ACTIVATING AIR BAG SYSTEM WARNING: Back-up power supply maintains air bag system voltage for about 90 seconds after battery is disconnected. After disabling air bag system, wait at least 90 seconds before servicing air bag system to prevent accidental air bag deployment and possible personal injury.
  • Page 5 REMOVAL & INSTALLATION . Disconnect right and left front seat belt pretensioners. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION . Disconnect right and left front air bag sensors. See FRONT AIR BAG SENSOR under REMOVAL & INSTALLATION . Fig. 3: Disconnecting Passenger-Side Air Bag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

  • Page 6: Operation Check

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 4: Disabling Air Bag System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ACTIVATING SYSTEM For Component Replacement Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform SYSTEM OPERATION CHECK .

  • Page 7: Disposal Procedures

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota DISPOSAL PROCEDURES WARNING: Undeployed air bags contain substances that can cause illness or injury if improperly handled. Disposing of an undeployed air bag may violate federal, state and/or local laws. If scrapping vehicle, air bag must be deployed while still mounted in vehicle.
  • Page 8 Because of heat, wait 30 minutes before handling driver-side air bag module. Seal deployed air bag module in vinyl bag and dispose of in usual manner. Fig. 5: Removing Driver-Side Air Bag Module Connector & Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 9 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 6: Securing Wire To Driver-Side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 10 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 7: Securing Driver-Side Air Bag Module To Wheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Passenger-Side Air Bag Module 1. Before proceeding, see SERVICE PRECAUTIONS . Remove passenger-side air bag module. See PASSENGER-SIDE AIR BAG under REMOVAL &...
  • Page 11 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 8: Preparing Passenger-Side Air Bag Module For Deployment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 12 Because of heat, wait 30 minutes before handling. Dispose of deployed pretensioner in usual manner. Fig. 9: Deploying Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POST-COLLISION INSPECTION When a vehicle has been involved in a collision, certain components of the passive restraint system must be inspected or replaced.

  • Page 13: Removal And Installation

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota REMOVAL & INSTALLATION WARNING: Failure to follow service precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS . After component replacement, check system operation. See SYSTEM OPERATION CHECK .

  • Page 14: Driver-Side Air Bag Module

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 10: Removing Air Bag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DRIVER-SIDE AIR BAG MODULE NOTE: If steering wheel horn button contact plate is deformed, replace steering wheel assembly.
  • Page 15 See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Fig. 11: Removing Driver-Side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT AIR BAG SENSOR Removal & Installation 1.
  • Page 16 4. To install, reverse removal procedure. Tighten front air bag sensor mounting screws to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Fig. 12: Removing Front Air Bag Sensors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

  • Page 17: Instrument Panel

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota INSTRUMENT PANEL Removal & Installation 1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. 2. Access and disconnect right and left seat belt pretensioner connectors. See SEAT BELT PRETENSIONERS .

  • Page 18: Passenger-Side Air Bag Module

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 13: Removing Instrument Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PASSENGER-SIDE AIR BAG MODULE NOTE: If instrument panel or instrument panel reinforcement is deformed, replace with new part.
  • Page 19 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Removal & Installation 1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. 2. Remove glove box door. Disconnect passenger-side air bag module connector. See Fig. 3 . Remove instrument panel.

  • Page 20: System Operation Check

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota 1. Before proceeding, see SERVICE PRECAUTIONS . Ensure front wheels are in straight-ahead position. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Remove steering wheel. See STEERING WHEEL .
  • Page 21 Using Toyota Hand-Held Tester Install Toyota hand-held tester to DLC1 or DLC3. DLC1 is located forward of right (passenger-side) front strut tower. See Fig. 14 . DLC3 is located under left side of instrument panel, to right of steering column. Read DTC...

  • Page 22: Clearing Codes

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 14: Identifying Data Link Connector 1 (DLC1) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLEARING CODES Using Jumper Wire 1. Use 2 jumper wires. Connect one end of first jumper wire to DLC1 terminal Tc and one end of second jumper wire to DLC1 terminal AB.
  • Page 23 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota cleared. Using Toyota Hand-Held Tester Connect Toyota hand-held tester to DLC1 or DLC3. Clear DTCs by following prompts on tester. See tester operator's manual for instructions. RELEASING SHORTING SPRING NOTE: Perform this procedure only if you were sent here from DIAGNOSTIC TESTS.
  • Page 24 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota...

  • Page 25: Diagnostic Tests

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 15: Releasing Shorting Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIAGNOSTIC TESTS WARNING: Failure to follow service precautions may result in air bag deployment and personal injury. See SERVICE PRECAUTIONS . After component replacement, check system operation.
  • Page 26 If fuse is okay, check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . Fig. 16: Identifying Air Bag Sensor Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR BAG WARNING LIGHT IS ILLUMINATED WITH IGNITION OFF Description AIR BAG warning light is located in instrument cluster.
  • Page 27 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota AIR BAG WARNING LIGHT INTERMITTENT If AIR BAG warning light comes on intermittently, perform following tests to simulate driving conditions. If problem cannot be found, replace all components including wiring harness.
  • Page 28 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota When DLC1 terminals Tc and E1 are connected together, air bag sensor assembly is set in Diagnostic Trouble Code (DTC) output mode. DTC is displayed by flashing AIR BAG warning light.
  • Page 29 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Possible Causes DTC 11/B0102 could be caused by a short to ground in squib circuit, squib malfunction, spiral cable malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 11/B0102 are displayed, disregard them.
  • Page 30 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 12/B0103 are displayed, disregard them. Diagnostic Procedure 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
  • Page 31 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Diagnostic Procedure 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring mechanism on connector C20 (center connector). See RELEASING SHORTING SPRING under DIAGNOSIS & TESTING. Measure resistance between terminals D+ (Yellow/Black wire) and D- (Yellow wire) of spiral cable side of upper spiral connector.
  • Page 32 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota NOTE: During testing, if DTCs other than DTC 14/B0101 are displayed, disregard them. Diagnostic Procedure 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between terminals D+ (Yellow/Black wire) and D- (Yellow wire) of spiral cable side of upper spiral cable connector.
  • Page 33 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Leave right front air bag sensor connected. 2. Measure resistance between air bag sensor assembly connector C20, terminals No. 9 (circuit SR+, Black/White wire) and No.
  • Page 34 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota voltage is more than one volt, go to next step. If voltage is less than one volt, replace right front air bag sensor. 12. Disconnect right front air bag sensor Yellow 2-pin sub-harness connector. Connector is located at right kick panel.
  • Page 35 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota 8. Connect jumper wire between White/Red and Brown wires of front air bag sensor side of sub-harness connector located at left kick panel. Measure resistance between White/Red and Brown wires of air bag sensor assembly side of front air bag sensor harness connector.
  • Page 36 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota connector C20, terminals No. 5 (circuit IG2, Black/Orange wire) and No. 6 (circuit ACC, Gray wire). See Fig. 16 . If voltage is more than 16 volts, check battery and charging system operation. If voltage is less than 16 volts, go to next step.
  • Page 37 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota See RETRIEVING CODES under DIAGNOSIS & TESTING. If DTC 51/B0107 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 51/B0107 is displayed, replace passenger-side air bag module.
  • Page 38 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Description The passenger-side air bag squib circuit consists of the air bag sensor assembly and passenger-side air bag module. The squib circuit causes the passenger-side air bag to deploy when deployment conditions are satisfied.
  • Page 39 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota DTC 54/B0106 could be caused by an open in Yellow/Red (circuit P+) and Yellow/Green (circuit P-) wires in passenger-side air bag squib circuit, passenger-side air bag squib malfunction or air bag sensor assembly malfunction.
  • Page 40 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota NOTE: During testing, if DTCs other than DTC 61/B0132 are displayed, disregard them. Diagnostic Procedure 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between ground and Yellow/Black wire (circuit PR+) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector.
  • Page 41 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota 1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Measure voltage between ground and Yellow/Black wire (circuit PR+) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector.
  • Page 42 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota SHORTING SPRING under DIAGNOSIS & TESTING. Measure resistance between Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. See WIRING DIAGRAMS . If resistance is less than one megohm, repair or replace harness or connector between seat belt pretensioner and air bag sensor assembly.
  • Page 43 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota between Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSIS &...
  • Page 44 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota CLEARING CODES under DIAGNOSIS & TESTING. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs.
  • Page 45 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota next step. If DTC 72/B0138 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect driver-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds.
  • Page 46 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSIS & TESTING. If DTC 73/B0135 is not displayed, system is functioning properly at this time.

  • Page 47: Torque Specifications

    1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Air Bag Sensor Assembly Screws 15 (20) Front Air Bag Sensor Mounting Screws 15 (20) Passenger-Side Air Bag Module Bolt 15 (20) Seat Belt Floor Anchor Bolt...
  • Page 48 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota...
  • Page 49 1999 Toyota RAV4 AIR BAG RESTRAINT SYSTEM 1999 Toyota Fig. 17: Air Bag System Wiring Diagram (RAV4)

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